Material Handling Oktri Mohammad - PowerPoint Presentation

Slide1

Material Handling

Oktri Mohammad

Firdaus

Rienna

Oktarina

Dodi PermadiSlide2

Material Handling

Material handling

is the function of

moving the right material

to the right place in the right time, in the right amount, in sequence, and in the right condition to minimize production cost.

The cost of MH estimates 20-25 of total manufacturing labor cost in the United States

[The Material Handling Industry of America (MHIA)]Slide3

Goals of Material Handling

The primary goal is to reduce unit costs of production

Maintain or improve product quality, reduce damage of materials

Promote safety and improve working conditions

Promote productivity

material should flow in a straight line

use gravity! It is free power

move more material at one time

mechanize material handling

automate material handlingSlide4

...

Goals

of Material Handling

Promote increased use of facilities

Reduce tare weight (dead weight)

Control inventorySlide5

Overview of Material Handling Equipment

Material handling equipment includes:

Transport Equipment

: industrial trucks, Automated Guided vehicles (AGVs), monorails, conveyors,

and

cranes

.

Storage Systems

: bulk storage, rack systems, shelving and bins, drawer storage, automated storage systems.

Unitizing Equipment

: palletizers

Identification and Tracking systemsSlide6

Considerations in Material Handling System Design

1. Material Characteristics

Category

Measures

Physical state

Size

Weight

Shape

Condition

Safety risk and risk of damage

Solid, liquid, or gas

Volume; length, width, height

Weight per piece, weight per unit volume

Long and flat, round, square, etc.

Hot, cold, wet, etc.

Explosive, flammable, toxic; fragile, etc.Slide7

...

Considerations

in Material Handling System Design

2. Flow rate

Manual handling

Hand trucks

Powered trucks

Unit load AGV

Conveyors

Conveyors

AGV train

High

Low

Long

Short

Move Distance

Quantity of

material

movedSlide8

...

Considerations in Material Handling System Design

3. Plant Layout

Layout Type

Characteristics

Typical MH Equipment

Fixed – position

Process

Product

Large product size, low production rate

Variation in product and processing, low and medium production rates

Limited product variety, high production rate

Cranes, hoists, industrial trucks

Hand trucks, forklift trucks, AGVs

Conveyors for product flow, trucks to deliver components to stations.Slide9

Layout & Material HandlingSlide10

LAYOUT & MATERIAL HANDLING

Tujuan

Perencanaan

Layout &

Mat

erial

Handl

ing

Memfasilitasi

proses

pengerjaan

produk

Meminimumkan penanganan materialMempertahankan

fleksibilitas operasi Mempertahankan kecepatan penyelesaian work in process

Menekan investasi pada peralatanMembuat ruangan

menjadi lebih ekonomisMengembangkan pemanfaatan tenaga kerja yang efektif

Memberikan keamanan, kesehatan, dan kenyamanan selama menyelesaikan pekerjaannyaSlide11

LAYOUT

Apa

ciri-ciri

bahwa

suatu

layout

dikatakan

baik

?

Terdapat

keterkaitan kegiatan yang terrencanaTerdapat aliran barang yang

direncanakanJalannya aliran lurusKegiatan mundur

kembali sangat sedikitAda aliran dari alat bantu

Aisles posisinya lurusAda penanganan material yang minimum antar operasiSlide12

...

LAYOUT

L

ayout

beradaptasi

dengan

perobahan

kondisi

kerja

Terdapat

minimum goods in processSuara-suara, debu, asap,

kotoran, kelembaban sangat terkendaliPenangan material secara manual minimum

sekaliFasilitas yang dibutuhkaan tenaga kerja untuk

mengerjakan tugasnya terpenuhi semuaOperasi awal berada di

dekat tempat menerima materialTempat menerima material dan mengirim barang

berada pada lokasi yang logisSpace cukup antar

fasilitasSlide13

Introduction to

Material Handling

ADVANCED

13Slide14

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Primary Handling activities

The primary handling objective in a warehouse is to sort inbound shipments according to precise customer requirements.

The three handling activities are

receiving,

in-storage handling, and

shipping. Slide15

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Receiving

Merchandise and materials typically arrive at the warehouse in larger quantities than when they depart.

The first handling activity required is unloading the transportation vehicle.

In most warehouses, unloading is manual.

Limited automated and mechanized methods have been developed that are capable of adapting to varying product characteristics. Slide16

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Receiving

…

Generally, one or two people unload a shipment.

The product is hand-stacked on

pallets

to form a unit load for movement efficiency.

In some cases,

conveyors

are employed to unload vehicles more rapidly.

Larger types of merchandise may be unloaded directly from the car or truck to be moved into the warehouse.Slide17

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Wooden

PalletsSlide18

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In-storage Handling

In-storage handling consists of all movement within a warehouse facility.

Following product receipt, it is necessary to transfer merchandise within the warehouse to position it for storage or order selection.

Finally, when an order is received, it is necessary to accumulate the required products and to transport them to a shipping area.

The two types of in-storage handling are

transfer

and

selection

.Slide19

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In-storage Handling

…

Transfer

There are at least two and sometimes three

transfer

movements required within a typical warehouse.

The merchandise is first moved into the building and placed at a designated storage location.

The inbound movement is handled by

forklift trucks

when pallets are used or other mechanical traction for larger unit loads. Slide20

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Forklift lifting another forkliftSlide21

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In-storage Handling

…

Transfer…

A second internal movement may be required prior to order assembly depending on the operating procedures of the warehouse.

When products are required for order selection, they are transferred to an order selection or picking area.

When the merchandise is physically large or bulky, such as a stove or washing machine, this second movement may be omitted.

In the final transfer, the assortment of products required for a customer shipment is moved from the warehouse to the shipping dock.Slide22

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In-storage Handling

…

Selection

The selection process groups materials, parts, and products into customer orders.

It is typical for one section of the warehouse to be established as a selection area to minimize travel distance.

The typical selection process is coordinated by a computerized control system.

The primary focus for warehouse automation is the selection process. Slide23

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Shipping

Shipping consists of checking and loading orders onto transportation vehicles.

As in receiving, shipping is manually performed in most systems.

Shipping with unit loads is becoming increasingly popular because considerable time can be saved in vehicle loading.

A unit load consists of grouped products, while a dead-stack or floor-stack load consists of boxes loaded directly from the floor.Slide24

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Basic Handling Considerations

Some guidelines for the design of material-handling systems are:

Equipment for handling and storage should be as standardized as possible.

The system should be designed to provide maximum continuous product flow.

Handling equipment should be utilized to the maximum extent possible.

In handling equipment selection, the ratio of deadweight to payload should be minimized.Slide25

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Basic Handling Considerations

…

Handling systems are classified as mechanized, semi-automated, automated, and information-directed.

A combination of labor and handling equipment is utilized in

mechanized

systems.

Generally, labor constitutes a high percentage of overall cost in mechanized handling.

Automated systems

, in contrast, attempt to minimize labor as much as practical by substituting capital investment in equipment. Slide26

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Basic Handling Considerations

…

When selected handling requirements are performed using automated equipment and the remainder of the handling is completed on a mechanized basis, the system is referred to as

semi-automated

.

An

information-directed

system uses computers to maximize control over mechanized handling equipment.

Mechanized handling systems are the most common.

However, the use of semi-automated and automated systems is rapidly increasing. Slide27

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Mechanized Systems

Mechanized systems employ a wide range of handling equipment.

The types of equipment most commonly used are

:

Forklift trucks,

Walkie

-rider pallet trucks,

Towlines,

Tractor-trailer devices,

Conveyors, and

Carousels. Slide28

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Forklift Trucks

Forklift trucks can move loads both horizontally and vertically.

A forklift normally transports a maximum of two unit loads (two pallets) at a time.

However, forklifts are not limited to unit-load handling. Slide29

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Forklift Trucks

…

A pallet or slip sheet forms a platform upon which loads are stacked.

A slip sheet consists of a thin sheet of material such as fiber or corrugated paper.

Slip sheets are an inexpensive alternative to pallets and are ideal for situations when product is handled only a few times.Slide30

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A sample slip sheet made of plastic

Plastic slip sheet

Packaging industry has found a lower cost, environmentally friendly, recyclable replacement for expensive, damage prone, short life wood pallets.

Plastic slip sheets are thin, strong sheets made of various plastic or rubberized materials. Slide31

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Plastic Slip sheets…

Slip sheet technology depends on special attachment to standard lift truck which enables the lift driver to either push or pull load of goods on top of slip sheet without the need of wood pallets.

Slip sheet under the loadSlide32

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Choosing the right lift truck

Choosing the best vehicle for your operation will result in optimal utilization of space and labor while maintaining a high safety factor.

Factors to consider when selecting a lift truck:

Fuel Types

Tire Types

Lift Capacity and Lift Height

Aisle Types

Truck Types

Attachments / Options

Slide33

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Fuel Types

Electric

Electric vehicles are designed for indoor use only.

Advantages are the absence of fumes and their quiet operation.

Gasoline or Diesel

Outdoor use only. 

Heavily used in construction

.

Slide34

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Fuel Types

…

LP

G

Liquid Propane

Advantages of using LP include minimal fumes

the ability to quickly change LP tanks

Fuel-cell Technology

hydrogen fuel cell power sources

providing the clean-air benefits of electricSlide35

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Tire Types

Cushion Tires

are

solid

tires generally with no tread pattern designed for use indoors on

smooth solid surfaces

.  

Pneumatic tires

require

air

and are designed for use outdoors on uneven and loose surfaces.  Slide36

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Lift Capacity and Lift Height

The lift capacity of a truck is affected by lift height and load size.

A larger size load moves the

center of gravity

of the vehicle and thus reduces the lift capacity. 

Attachments also affect the capacity of a truck. 

If there are any changes made to the truck — like adding an attachment — load capacities should be revised.  Slide37

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Lift Capacity

…

Why spend so much time on capacity? 

Why not just play it safe and get a higher capacity truck? 

The answer is size.

Bigger is not necessarily better in warehousing. 

A higher capacity truck will be physically larger and require larger aisles

.Slide38

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Aisle Types

Wide Aisle

.

  Standard forklifts fall into this category of trucks designed to work in aisles greater than 11' wide.

Narrow Aisle

(NA)

trucks operate in aisles of 8' to 10' and are generally stand up vehicles such as Reach Trucks.Slide39

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Aisle Types

…

Very Narrow Aisle

(VNA)

trucks operate in aisles less than 6' and often use guidance systems (wire, rail, or optical) to travel within the aisles. 

Types of VNA trucks are Order Selectors, Swing Mast, and Turret Trucks

Wide Aisle and Narrow Aisle trucks are designed to

turn

in the aisle while Very Narrow Aisle trucks

do not turn

within the aisle Slide40

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Truck Types

Lift Trucks have come a long  way since first being introduced in the early part of the 20th century as can be seen in this early photo of an

Ellwell-Parker

"Tiering Tructor".  

Their original purpose, the efficient movement of materials, however has not changed.  Slide41

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Truck Types

1- Standard forklift

The standard forklift, also known as a counterbalanced lift truck, is the vehicle most people think of when they think Lift truck or Forklift. 

It is available with any of the fuel types and tire types as well as numerous weight capacities, lift heights and attachment options.

If you are running a small operation and will only have one truck, this is probably the vehicle for you.  Slide42

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STANDARD

FORKLIFT

3,000 - 8,000 lb. Capacity

2.0 Liter or 2.5 or 2.7 Liter industrial engines

Gas / LPG / Diesel / Electric Power (with battery)Slide43

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Truck Types

1- Standard forklift

…

The standard forklift is a wide aisle truck which requires at least 11' aisles to turn in. 

The aisle width is determined by the size of the truck, the turn radius, and the size of the load. 

Available options and attachments include side shifts, fork shifts, hydraulic clamps, and slip sheet attachments, to name a few. 

Standard forklifts are usually used for lift heights under 20 feet (

~ 6 meters)

.Slide44

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Truck Types

2- Reach truck

The reach truck is a

narrow aisle truck

designed specifically for racked pallet storage. 

It consists of outriggers in front and telescoping forks that use a hydraulic scissors-type mechanism that allows you to pick up the load and retract it over the outriggers.

This reduces the overall truck and load length, allowing you to turn in a narrower aisle. Slide45

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Truck Types

2- Narrow aisle reach truck…

Reach trucks are designed for racking areas only and do not work for loading trucks or quickly moving loads over distances. 

Other Names

of reach trucks are: Stand-up reach, Straddle reach , Double-deep reach

Slide46

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Truck Types

2- Reach truck

…

Narrow aisle truck designed specifically for racked pallet storage. 

Double-deep version (shown) loads pallets 2-deep in special double-deep racking.Slide47

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Truck Types

2- Reach truck

…

Operator training on reach trucks tends to take longer than on other vehicles due to the complexity of the controls.

Double-deep reach trucks use an extended reach mechanism which allows you to store pallets t

o

o deep in specially designed double-deep rack. 

Reach trucks are available with lift heights up to 30 feet (

~ 10 meters)

.Slide48

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Truck Types

3

- Motorized pallet truck

Other Names include:

Walkie, Walkie-rider, Rider 

They come in "Walkie" versions or "Rider" versions. 

As you would expect the walkie is designed for the operator to walk along with the truck as they move loads, while the Rider has a small platform which the operator stands on. 

The riders work great for frequent moving of loads over extended distances within warehouses and manufacturing operations.  Slide49

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WALKIE TRUCKSSlide50

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Motorized Pallet Truck

(Rider Type)

Low cost and high maneuver

-

ability make these vehicles a good choice where frequent movement of loads is required. 

Options include double pallet length forks that allow you to move 2 pallets in one trip. Slide51

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Truck Types

3

- Motorized pallet truck

…

They are fast and highly maneuverable.

Minimal controls result in short learning curves for operators. 

If you are looking for an inexpensive method for moving loads from point A to point B, a rider may

be

the answer. 

If you are moving heavy loads short distances and are looking for an employee-friendly option to the pallet jack, check out a walkie.Slide52

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Truck Types

4

- Order selector

Designed specifically for manual handling of less-than-pallet-load quantities in racking. 

It has fixed forks attached to a platform which elevates the load and the operator to facilitate manual loading and unloading from racking. 

Order Selectors are very narrow aisle vehicles which operate in aisles of less than 6'. 

Order selectors are available in lift heights up to 40 feet however 20 to 30 foot models are more common.Slide53

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Order Selector Truck

Elevates the load and the operator to facilitate manual loading and unloading from rackingSlide54

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Order Selector Truck

…

Vehicle is designed specifically for hand loading less-than-pallet load quantities into and out of selective rack.  Slide55

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Attachments / Options

There is an enormous variety of attachments  and options available for lift trucks. 

While most attachments are designed for use on standard lift trucks, some of them are also used on reach trucks and VNA trucks. 

Most attachments will change the capacity of the lift truck.  Slide56

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Common types of attachments

1-

Sideshift

is the most common attachment. 

The sideshift device allows the fork carriage to slide

left and right

to allow more accurate placement of the load. 

Sideshifts will increase productivity and safety as well as reduce product damage by allowing the operator more flexibility in load placement.Slide57

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Common types of attachments

…

2- Fork positioner

 allows the operator to adjust the distance between the forks

without

getting off of the truck. 

Used primarily in high volume operations where there is a great variety of pallet sizes.

3- Fork pivot

 allows the forks and carriage to pivot (rotate).  Slide58

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Common types of attachments

…

4-

Paper roll clamp.

  Designed specifically for the handling of large paper rolls, the paper roll clamp clamps around the roll and also allows for a full 360 degree rotation.

5-

Prongs.

  A Prong is a specialized rod type attachment used for picking up rolls of materials such as carpet rolls, wire and cable spools, and rolled steel, by inserting the prong into the center of the spool.

6-

Fork extensions.

  Fork extensions slide over the existing forks on the truck to allow you to pick up longer loads.Slide59

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Conveyor Systems

Conveyor systems have been a mainstay of material handling for over 100 years.  Slide60

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Conveyor Systems

…

Belt conveyors were moving materials in manufacturing plants before the forklift was even invented. 

New configurations and sophistication of controls have kept conveyor systems in the state-of-the-art category with other automated material handling systems. 

Conveyor is very cost effective and the ease of expandability and reconfiguration makes it ideal for growing operations.  Slide61

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Gravity Skate Wheel Conveyor

Gravity flow skate wheel conveyor is a low cost option for conveying lightweight cartons or trays. 

Used extensively in shipping/receiving and assembly areas, skate wheel conveyors reduce manual material handling of lightweight items over short distances.  Slide62

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Gravity Roller Conveyor

Application for gravity roller conveyor is similar to that of gravity skate wheel. 

Its cost is a little higher and it is more effective where heavier items are being handled. Slide63

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Automated Belt Conveyor

Automated belt conveyer has similar applications to gravity roller and skate wheel.

Single units can be incorporated into gravity conveyor systems to create a simple low cost semi-automated system.  Slide64

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Flexible Conveyor

Used extensively in shipping/receiving operations for package handling, flexible conveyor is usually anchored at one end to fixed gravity or automated conveyor allowing the other end to be expanded and flexed into trailers for loading and unloading.Slide65

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Unit Load Conveyor

Unit Load Conveyor is a heavy duty version of roller conveyor used for handling pallet loads or larger trays.  Slide66

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High Volume Trailer Loading

This shows an application of conveyor in high volume trailer loading/unloading

.Slide67

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Sortation Systems

Sortation systems are the key to large elaborate conveyor systems. 

The variety of sortation systems is extensive as are their applications. Slide68

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Automated

Equipment

While you will need deep pockets for some of this equipment, the increase in productivity and storage capacity can provide a reasonable ROI in many operations.Slide69

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Horizontal Carousel

Horizontal Carousels

are used in high-volume

small-parts

picking operations.

Generally, an operator will run 2 to 4 carousels at a time avoiding the need for the operator to wait while one unit is turning.  Slide70

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Vertical Carousels

Vertical Carousels

consist of a series of horizontal trays on a vertical carousel. 

Vertical carousels are most effective when floor space is at a minimum and there is ample overhead clearance.  Slide71

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Vertical Carousels

…

Enclosed vertical carousels offer additional security and protection for the product stored in them.

Vertical carousels are frequently used in laboratories, offices, and specialty manufacturing operations.  Slide72

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Automated Storage and Retrieval System (ASRS)

A system of rows of rack, each row has a dedicated retrieval unit that moves vertically and horizontally along the rack picking and putting away loads.  Slide73

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Automated Storage and Retrieval System (ASRS)

…

ASRS systems are available in

Mini-load types

  which store and transfer product on some type of tray or in bins and

Unit-load types

(shown) which transfer and store pallet loads. Slide74

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Automated Guided Vehicle (AGV)

Vehicles that can be programmed to

automatically

drive to designated points and perform preprogrammed functions. 

Guidance system may consist of a wire embedded in the floor, special tape, laser and optical system. Slide75

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Automated Guided Vehicle

…

They are most effective where highly repetitive tasks are performed over extended distances. 

The variety in configurations of AGVs  is endless, virtually any type of material handling equipment can be converted to an AGV.   Slide76

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Automated Guided Vehicle

…

This is another version of an AGV that has added functionality to raise and lower the pallet to different heights. Slide77

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Towline (

AGV

) system

Towline system is designed for movement of materials and products over paths.Slide78

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Towline system

…

Towed vehicles can be manually engaged or disengaged anywhere along the route or automatically activated at pre

-

selected stations.

Sophisticated controls route vehicles along the main path and switch them into pre

-

selected side routes.

When disengaged, vehicles can manually be routed through inspection, order checking or unloading operations.Slide79

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Dock Equipment

The loading dock is generally considered the most dangerous part

of

a material handling operation. 

Every year there are numerous injuries when lift trucks drive off the edge of a dock or fall between the dock and the trailer.

The number one concern when purchasing dock equipment should be safety.Slide80

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Standard Pull-chain mechanical Dock Leveler

Dock levelers are used to bridge the gap between the dock and the trailer and adjust for any height differences. 

The pull-chain

mechanical

dock leveler is the most common type used. Slide81

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Standard Pull-chain mechanical Dock Leveler

It is important to know the weight capacity of the dock levelers. 

It is also important to have regularly scheduled preventative maintenance performed on dock levelers.Slide82

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Hydraulic Dock Leveler

A step up from the mechanical dock leveler, the hydraulic dock leveler uses an electric pump and hydraulic cylinder to engage/disengage the dock leveler. 

This works from a remote switch which is generally mounted on the wall next to the dock. 

Docks with high volume will benefit from this automation. Slide83

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Truck Restraint:  ICC Bar Type

The most dangerous aspects of loading and unloading trailers is when a driver starts to pull away from the dock while he is still being loaded. 

The ICC Bar type restraints automatically engage the rear guard on the trailer when it backs into the dock. 

After the trailer is loaded/unloaded  the restraint is disengaged via a control panel Slide84

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Truck Restraint:  Automatic Wheel Type

Another automated truck restraint system, the wheel type system engages in front of the rear wheels of the trailer

.Slide85

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Elevating Docks

Elevating docks are used where a raised dock is not available. 

They operate via an electric pump and a hydraulic lift cylinder. Slide86

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Dock Seals

Dock seals come in a variety of configurations and are used to prevent air, dirt, insects, birds, and rain/snow from entering the building while loading and unloading trucks

.Slide87

Thank you ...

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